PRECAUTIONS
GI-47
< PRECAUTION >
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After installing plate clamps, apply force to them in the direction of
the arrow, tightening rubber hose equally all around.
Precaution for Engine OilsINFOID:0000000001606123
Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact
with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS
Avoid prolonged and repeated contact with oils, particularly used engine oils.
Wear protective clothing, including impervious gloves where practicable.
Do not put oily rags in pockets.
Avoid contaminating clothes, particularly underpants, with oil.
Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-
larly.
First aid treatment should be obtained immediately for open cuts and wounds.
Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Prepara-
tions containing lanolin replace the natural skin oils which have been removed.
Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice without delay.
Where practical, degrease components prior to handling.
Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face
shields; in addition an eye wash facility should be provided.
Precaution for Air ConditioningINFOID:0000000001606124
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
HA section "HFC-134a (R-134a) Service Procedure", "REFRIGETANT LINES" for specific instructions.
SMA022D
GI-48
< PRECAUTION >
LIFTING POINT
LIFTING POINT
Special Service ToolINFOID:0000000001606131
CAUTION:
Every time the vehicle is lifted up, maintain the complete vehicle curb condition.
Since the vehicle's center of gravity changes when removing main parts on the front side (engine,
transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission
jack or equivalent.
Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle,
suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equiv-
alent.
Be careful not to smash or do not do anything that would affect piping parts.
Garage Jack and Safety Stand and 2-Pole LiftINFOID:0000000001606132
WARNING:
Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes, tubes,
etc. under the vehicle.
Never get under the vehicle while it is supported only by the jack. Always use safety stands when
you have to get under the vehicle.
Place wheel chocks at both front and back of the wheels on the ground.
When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of
the vehicle are well balanced.
When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and
sill spoiler.
Tool number
Tool nameDescription
LM4086-0200
Board on attachment
LM4519-0000
Safety stand attachment
S-NT001
S-NT002
PRECAUTIONS
HA-9
< PRECAUTION >
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When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow “Maintenance of Oil Quantity in Compressor”
exactly. Refer to HA-19, "
Maintenance of Oil Quantity in Compressor".
Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with oil, wipe
it off by using a clean waste cloth moistened with thinner.
After compressor service operation, turn the compressor shaft by hand more than five turns in both
directions. This will equally distribute oil inside the compressor. After the compressor is installed,
let the engine idle and operate the compressor for one hour.
After replacing the compressor magnet clutch, apply voltage to the new one and check for usual
operation.
Precaution for Service EquipmentINFOID:0000000001396434
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
VACUUM PUMP
The oil contained inside the vacuum pump is not compatible with the
specified oil for HFC-134a (R-134a) A/C systems. The vent side of
the vacuum pump is exposed to atmospheric pressure. So the vac-
uum pump oil may migrate out of the pump into the service hose.
This is possible when the pump is switched off after evacuation (vac-
uuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows.
Usually vacuum pumps have a manual isolator valve as part of the
pump. Close this valve to isolate the service hose from the pump.
For pumps without an isolator, use a hose equipped with a manual
shut-off valve near the pump end. Close the valve to isolate the
hose from the pump.
If the hose has an automatic shut-off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is open
and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2″-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified oils.
SERVICE HOSES
RHA270DA
SHA533D
HA-24
< ON-VEHICLE MAINTENANCE >
FLUORESCENT LEAK DETECTOR
FLUORESCENT LEAK DETECTOR
Checking System for Leaks Using the Fluorescent Leak DetectorINFOID:0000000001396445
1. Check A/C system for leaks using the UV lamp and safety goggles J-42220 in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner J-43872 to prevent future misdiag-
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and oils, may falsely trigger the leak detector. Make sure the surfaces to be checked are
clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionINFOID:0000000001396446
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2, 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool J-41459.
3. Connect the injector tool to the A/C low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
COMPRESSOR
HA-33
< ON-VEHICLE REPAIR >
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6. Remove bolts (A) from compressor (1), using power tools.
7. Remove compressor (1) downward from the engine compart-
ment.
INSPECTION FOR CLUTCH DISC TO PULLEY CLEARANCE
1. Check the clearance around the entire periphery of the clutch disc.
Measure the clearance for the compressor as shown.
2. If specified clearance is not obtained, replace compressor.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with a new ones, and
apply compressor oil when installing.
When recharging refrigerant, check for leaks. Refer to HA-22, "
Checking of Refrigerant Leaks".
SJIA0672E
Clutch disc to pulley clearance : 0.3 - 0.6 mm (0.012 - 0.024 in)
RHA087E
COMPRESSOR
HA-35
< ON-VEHICLE REPAIR >
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1. Check the clearance around the entire periphery of the clutch disc.
Measure the clearance for the compressor as shown.
2. If specified clearance is not obtained, replace compressor.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with new ones, and
apply compressor oil when installing.
When recharging refrigerant, check for leaks. Refer to HA-22, "
Checking of Refrigerant Leaks".
Removal and Installation of Compressor - K9KINFOID:0000000001523297
K9K
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant. Refer to HA-29, "HFC-134a (R-134a)
Service Procedure".
2. Remove the engine cover.
3. Remove the front grille. Refer to EXT-19, "
Removal and Installation". Clutch disc to pulley clearance : 0.3 - 0.6 mm (0.012 - 0.024 in)
RHA087E
ALIIA0094GB
HA-36
< ON-VEHICLE REPAIR >
COMPRESSOR
4. Reposition the RH air guide out of the way.
5. Remove the nut (A) to disconnect the low-pressure flexible hose
(1) from the compressor, and disconnect the high-pressure flexi-
ble hose from the compressor.
CAUTION:
Cap or wrap the joint of compressor, low-pressure flexible
hose and high-pressure flexible hose with suitable material
such as vinyl tape to avoid the entry of air.
6. Remove the front RH wheel and tire.
7. Remove the engine undercover, using power tools.
8. Reposition the fender protector out of the way.
9. Remove the A/C drive belt. Refer to EM-263, "
Removal and Installation".
10. Remove the compressor harness connector (A), then remove
the bolts (B) from the compressor (1), using power tools.
11. Remove the compressor downward from the engine compart-
ment.
INSPECTION FOR CLUTCH DISC TO PULLEY CLEARANCE
1. Check the clearance (B) around the entire periphery of the
clutch disc (1) and pulley (2) using a suitable tool (A) as shown.
2. If the specified clearance (B) is not obtained, replace the com-
pressor.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with new ones, and
apply compressor oil when installing.
E1KIA0036GB
E1KIA0038ZZ
E1KIA0039ZZ
Clutch disc to pulley clearance (B) : 0.3 - 0.6 mm
(0.012 - 0.024 in)
AWIIA0273ZZ
HA-38
< ON-VEHICLE REPAIR >
LOW-PRESSURE FLEXIBLE HOSE
LOW-PRESSURE FLEXIBLE HOSE
Removal and Installation of Low-Pressure Flexible Hose - MR18DE, HR16DE
INFOID:0000000001404150
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant. Refer to HA-21, "HFC-134a (R-134a)
Service Procedure".
2. Remove engine cover.
3. Remove cowl top cover. Refer to EXT-20, "
Removal and Installation".
4. Remove lower dash insulator.
5. Remove ground wire harness (1).
6. Remove bolt (A) and nut (B) from low-pressure flexible hose (2)
bracket.
7. Remove bolt (A), and then disconnect low-pressure flexible
hose (1) and high-pressure pipe (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
8. Remove nut (A), and then remove low-pressure flexible hose (1)
from compressor (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
When recharging refrigerant, check for leaks. Refer to HA-22, "
Checking of Refrigerant Leaks".
Removal and Installation of Low-Pressure Flexible Hose - K9KINFOID:0000000001527624
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant. Refer to HA-21, "HFC-134a (R-134a)
Service Procedure".
SJIA0675E
SJIA0644E
SJIA0676E